ELECTRICAL TESTS AFTER INSTALLATION — LV / HV CABLES MEGGER TEST VOLTAGE TEST for 5 minute for new Cables Voltage grade of POUR ater teeta d [oem ora list st et) eo 0.65/1.1 kV 500 Volt 0.65/1.1 kV 3.0 1.9/3.3 & 3.3/3.3 1000 Volt 1.9/3.3 kV 5.0 ky 3.3/3.3 kV 9.0 3.8/6.6 kV 1000 Volt 3.8/6.6 kV 10.5 6.6/6.6 kV & 1000 Volt 6.35/11 kV 6.6/6.6 ae 6.35/11 18.0 11/11 kV & 2500 Volt 12.7/22 kV 11/11 kV 30.0 19/33 kV 2500 Volt Pemeen Ble 19/33 kV 60 GENERALLY DC TEST IS PREFERRED AS TEST EQUIPMENT REQUIRED 1S COMPACT, EASILY PORTABLE & POWER REQUIREMENTS ARE LOW. NOWADAYS VLF (VERY LOW FREQUENCY) TEST EQUIPMENT @ FREQUENCY OF 0.1 HZ ARE AVAILABLE IN MARKET. SLES & WIRES | FANS | LIGHTING | SWITCHES & SWITCHGEAR | uPVC CONDUITS | APPLIANCES | PUMPS | GEYSERS POLYCASCable Laying: Care should be taken to ensure that cable is not twisted as it is installed. Precautions should be taken to avoid mechanical damage to the cables before and during installation. The cables should not be bent to a sharp radius. Wherever possible, larger radii should be used. Cables damaged during installation can cause service failures. Mechanical stresses during installation are normally more severe than those encountered while in service. Water has very harmful effect on the electrical performance of XLPE cables. It is strongly advised to take special care in avoiding water from penetrating the cable in transporting, storing, laying. terminating, and jointing of cables. Such waterproof measure is the key factor in trouble-free operation of cables. IS 1255 is the standard for Code of Practice for installation and maintenance of Power cables. This standard may be referred for installation, jointing and maintenance of cables. Few precautions to be taken during installation are given in next page. ® CABLES & WIRES | FANS | LIGHTING | SWITCHES & SWITCHGEAR | uPVC CONDUITS | APPLIANCES | PUMPS | GEYSERS POLYCAB maLIFTING CABLES FROM TRUCK DO NOT DROP CABLE DRUMS FROM TRUCKS | LIFTING CABLE DRUMS USING CRANE BEAM WRONG CORRECT CORREC! POSITION POSITION POSITION USE CRANE or HOIST to unload drums from Truck or Trailer. Also use winch, forklift or makeshift ramp. ® wc) wires. POLYORE Connection ZindaaHANDLING & SHIFTING OF CABLE DRUMS 00 IF A FORKLIFT IS USED FOR HANDLING & SHIFTING OF CABLE DRUMS, THEN FORK SHALL APPROACH DRUM FROM FLANGE SIDE. THE FORK SHALL BE POSITIONED SUCH THAT THE CABLE DRUM IS LIFTED WITH BOTH THE CABLE DRUM. FLANGES. ® ee: Connectinn Zindaai KaUNREELING CABLE FROM DRUM BIRD CAGING is a defect caused due to twist of cable due to improper unreeling. It results outer sheath cracks or cuts or armour swelling. The technique of pulling cables from drum plays important role in this case. While removing cable from drum, always put drum on Jacks & pull the cable. If drum is kept on flange & removed the cable then there will be 100% chances of Bird cagingUNREELING CABLE FROM DRUM > |mproper handling can cause damage to the cable which may weaken the cable components, and cause failure in due course. Care must be taken to select a suitable position for the cable drum jacks in order to ensure that the drum may be raised and rotate with full safety. The jacks therefore be placed on a firm support of thick boards. > Care should be taken to exert a steady pull avoiding any jerks. Twisting or kinking of cable is very dangerous as this may cause damage to small sizes of conductors, insulation & sheath. Shifting and knife edging of the armoring and damage to the serving etc. Care should be taken to avoid short bends and consequent straining of conductors. > Proper handing of Cables is very important both for safety as well long life of the installations. Mishandling of Cables is the main cause of cable failures. This can be prevented by winding the cables by loading drums on jacks & pulling cables in the proper direction with stocking or pulling eye. For longer lengths or higher weight/ diameter of cables can be pulled with pulling eyes whereas smaller length of light weight cables cab ne pulled by manually or by mechanical means. ©REPAIRS TO OUTER SHEATH During cable drum unpacking, rewinding or laying damage to outer sheath may accidentally occurs. If the cable underneath appears to be in good condition, repairs to localized damage at site may be carried out as suggested in the following alternative methods. The objective is that there is no possibility of moisture ingress through damage to armour or other parts of the cable when it is in its final installation position. a) The local area of damage to be cleaned with a suitable solvent. A patch is then applied to fill the area using approved grade of special putty e.g. BICASEAL. This is followed by an overlapped layers of 50 mm wide PIB self amalgamating tape with 50 % overlap. b) Clean the local area with a suitable solvent. Apply heat shrinkable sleeve with required size. Apply heat over the sleeve till it shrinks properly over the outer sheath. ©LT XLPE / LT PVC CABLES 1 a) b) PROCEDURE FOR MEGGER TEST AT SITE Remove the planks at the place Indicated as “cable end” To take out running end of cable Remove 300 mm outer sheath, Armour, Inner sheath from the both ends of Cable. Remove 100 mm Insulation (XLPE/PVC) & expose conductor. Connect Voltage lead of megger to Conductor & earth lead of megger to balance all cores + armour. Give 1000 Volts to conductor, wait for a minute & note megger Value after one minute. Repeat this procedure for all cores.JS = 1. Remove the planks at the place Indicated as “cable end’ to take out running end of 3. Remove the external layers Outer sh. /armour/ inner sheath (Approx- 30cm) 5. Remove the semi-conducting Layer(- Black) from all the cores at both ends( 20 cm)( A glass piece may be used for the purpose with safety) “ =~ 2. Take out the running and bottom 4 Remove the copper tape ends as above From both endsIMPORTANT INSTRUCTION Note: 1. Never keep ends of cable in open condition. Always cables / samples to be kept in with proper end caps. If moisture ingress inside the cable, it will damage, armor, copper tape & cable leads to failure. 2. Proper lugs to be used for best results. Improper lugs will lead to heating of the cables at termination. 3. Sector shaped lugs to be used for sector shaped cables. ® > wis. OLR be Connection Zindaai KaCABLE LAYING - PLANNING Selection of cable Route Mode of Installation. » UNDERGROUND » IN DUCT OR CABLE LADDER / TRAYS Associated accessories. Manpower Inspection of Cable Route Excavation(Trenching) & Preparation of Cable Bed. Laying of necessary pipes Drum handling & Cable Pulling Equipment including Pay Off Jacks. Arrangement of Filling. = wits, ® POLYCAB b Connection Zindaai KaThe cable Route is First Inspected as per the main plan for visible obstruction such as Trees, Main Holes, Road Crossing etc.* After proper marking of the Route, the excavation is started. Generally Excavation is done manually however, depending on the terrain other methods such as mechanical force, thrust bore or trench plugging can be employed compressed air tools are used for breaking rocks and excavation across Road. Connection Zindaai KaDEPTH OF LAYING * As general Route, the desired depth of cable for underground laying is as under. LV POWER & CONTROL CABLES : 0.75 m “ HV POWER CABLES UPTO 11 kV : 0.90 m + HV POWER CABLE 22 & 33 kV: 1.05 m * EHV POWER CABLE : 1.2 m ® POLYCAB Connection Zindaai KaCABLE LAYING — ABC CABLES * Main thing in laying of ABC XLPE Cable of laying skill manpower to doing termination with good knowledge of all along accessories. * Take care of every bending according to the dia. Of the cable * And main thing doing earth to the messenger most of the problem happen because in field the forget to earth megger. ® POLYCAB Connection Zindaai KaCABLE LAYING — ABC CABLES * The phase conductors shall be provided with one, two or three ‘ridges’ OR Color identification Tape Red yellow & blue. * so that according to it connection properly with same phase to get proper continuity of the that system. * And hand the messenger with proper way with the clam so that not too much stress on the other phase and it give better healthy condition for long time of cable O} <> wanes POLHORE DL Connection Zindeai KaCLEARANCE * The desired minimum Clearances are as under Power to Control Cables Fe ’ Power to Communication Cable Power Cables to Gas/Water Main :- 0.3 ® SD wins POLNCARWIDTH OF TRENCH * The Width of Trench Depends on no diameter of cables to be laid. No of Cables HV CABLES | EHV CABLES 3 0.65m 0.80 m 4 0.85 m 1.05m © <=) wis OLR D Connection Zindaai KaSAND BEDDING * Sand bedding of minimum 10 cm is provided for the cables laid directly in ground protection. * The grain size of sand should be preferably be less than 8 mm.LAYING IN DUCTS / PIPES Sheet cast Iron, Plastic, Cement or earthen ware duct or cable ducting blocks are used for cable crossing roads/ railway tracks. Spare ducts for future expansions should also be provided and should be properly sealed off. Buried ducts or ducting block should project into footpath or up to the edge of road, where there is not footpath to permit smooth entry of cable with out undue bending. The duct/pipe should be mechanically strong to withstand the impact due to traffic when laid across road/railway tracks. @ <=) wires, POLYORS Connection Zindoui KaLAYING IN DUCTS / PIPES The pipe/ducts are generally laid at depth 1.0 & 1.2 mtr across road & railway track respectively. The diameter of duct or pipe should be at least 1.5 times the outer diameter of cable. Single core cable should never be laid individually in steel duct. However, it is permissible to lay all three cables of same system in come duct. ® SD wines. POLCAR |LAYING OF SINGLE CORE CABLES IN PARALLEL Flat Vertical e:@ Flat Horizontal Trefoil Horizontal & & ® SD wines POLYCRCABLE LAYING ACCESSORIES Always pull the cable from top while = 2 mq = - <. drum mounted on suitable jacks = = L 7 XY with proper shaft. Arrow marked on drum is for direction of rolling drum > 4 5 | on ground and not for pulling cable ey { Saf from drum. ES orn” 2 @ = wines POWER,MINIMUM BENDING RADIUS RECOMMENDED MINIMUM BENDING RADIUS FOR HT / LT / SINGLE CARE UNSHEATHED CABLES Cable Type Single Core UY IT im oye) HT Cables 20xD 15xD LT Cables 15xD 12xD RYT 4 (Mn &eye 1 8xD = Oats Latet ® = wins, POLYGAG,CRACKS ON LT XLPE INSULATION BO : In XLPE due to Ultra-Violet rays (Sun ‘ light )after some timeCRACKS ON LT XLPE INSULATION Vcover XLPE insulation with Heat Shrinkable!” Black tape at termination and ensure no xcpel a Is exposed to Sunlight * Apply, Red, Yellow, Blue &Black PVC Tape at ends for Phase Identification and Then Connect the cable.INSTALLATION PRACTICE Maintain the specified bending radius for safe operation @ SD wines POLICECONDUIT SELECTION Always use correct size of conduit (For effective cooling) Do not use lower size of conduit